US11063320B2 - Terminal busbar - Google Patents

Terminal busbar Download PDF

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Publication number
US11063320B2
US11063320B2 US16/242,058 US201916242058A US11063320B2 US 11063320 B2 US11063320 B2 US 11063320B2 US 201916242058 A US201916242058 A US 201916242058A US 11063320 B2 US11063320 B2 US 11063320B2
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United States
Prior art keywords
fusible member
busbar
thermoplastic layer
thermoplastic
overmolded
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active, expires
Application number
US16/242,058
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English (en)
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US20200220143A1 (en
Inventor
Heekook Yang
Robert Merriman
Jivitha Siddharthan
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LG Energy Solution Ltd
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LG Chem Ltd
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Filing date
Publication date
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Assigned to LG CHEM, LTD. reassignment LG CHEM, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MERRIMAN, Robert, YANG, HEEKOOK
Priority to US16/242,058 priority Critical patent/US11063320B2/en
Assigned to LG CHEM, LTD. reassignment LG CHEM, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SIDDHARTHAN, Jivitha
Priority to PCT/KR2020/000128 priority patent/WO2020145581A1/fr
Priority to KR1020207035315A priority patent/KR102757238B1/ko
Priority to EP20737976.9A priority patent/EP3793032A4/fr
Priority to JP2021518415A priority patent/JP7118499B2/ja
Priority to CN202080003233.0A priority patent/CN112292746B/zh
Publication of US20200220143A1 publication Critical patent/US20200220143A1/en
Publication of US11063320B2 publication Critical patent/US11063320B2/en
Application granted granted Critical
Assigned to LG ENERGY SOLUTION, LTD. reassignment LG ENERGY SOLUTION, LTD. ASSIGNMENT OF ASSIGNOR'S INTEREST Assignors: LG CHEM, LTD.
Active legal-status Critical Current
Adjusted expiration legal-status Critical

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/22—Bases, e.g. strip, block, panel
    • H01R9/24—Terminal blocks
    • H01R9/26—Clip-on terminal blocks for side-by-side rail- or strip-mounting
    • H01R9/2625—Clip-on terminal blocks for side-by-side rail- or strip-mounting with built-in electrical component
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/572—Means for preventing undesired use or discharge
    • H01M50/574—Devices or arrangements for the interruption of current
    • H01M50/581—Devices or arrangements for the interruption of current in response to temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/05—Component parts thereof
    • H01H85/055—Fusible members
    • H01H85/06—Fusible members characterised by the fusible material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/05—Component parts thereof
    • H01H85/055—Fusible members
    • H01H85/08—Fusible members characterised by the shape or form of the fusible member
    • H01H85/11—Fusible members characterised by the shape or form of the fusible member with applied local area of a metal which, on melting, forms a eutectic with the main material of the fusible member, i.e. M-effect devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/505—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising a single busbar
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
    • H01M50/51—Connection only in series
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2200/00—Safety devices for primary or secondary batteries
    • H01M2200/10—Temperature sensitive devices
    • H01M2200/103—Fuse
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/211—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for pouch cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the inventors herein have recognized a need for an improved terminal busbar. If a terminal busbar conducts an excessive current from the battery module for an extended time interval, the battery module may be damaged. Further, a portion of a terminal busbar may melt and become dislodged from the remaining portion of the terminal busbar into the air. Still further, the inventors herein have recognized that when a portion of the terminal busbar melts, secondary arcing may occur between a melted portion of the terminal busbar and a remaining portion of the terminal busbar.
  • the inventors herein have recognized that it would be advantageous to have a terminal busbar that protects a battery module from an excessive current condition for an extended time period by transitioning to an open electrical state, and to prevent melted portions of the terminal busbar from being dislodged from the terminal busbar into the air during the excessive current condition, and to prevent secondary arcing between a melted portion of the terminal busbar and a remaining portion of the terminal busbar.
  • the terminal busbar includes a first busbar portion having a coupling plate.
  • the terminal busbar further includes a second busbar portion having a top plate portion and first and second side plate portions coupled to and extending downwardly from the top plate portion.
  • the terminal busbar further includes a fusible member coupled to and between the coupling plate of the first busbar portion and the top plate portion of the second busbar portion and being electrically conductive.
  • the fusible member having a top surface, a bottom surface, and a first portion with a groove or an aperture extending therethrough.
  • the terminal busbar further includes an overmolded thermoplastic layer encapsulating the first portion of the fusible member and the groove or the aperture.
  • the overmolded thermoplastic layer having a first thermoplastic portion disposed on the top surface of the fusible member, and a second thermoplastic portion disposed on the bottom surface of the fusible member.
  • a thickness of the first thermoplastic portion is greater than or equal to the thickness of the fusible member along an axis.
  • the axis extends through the overmolded thermoplastic layer and the fusible member and is perpendicular to the top and bottom surfaces of the fusible member.
  • a thickness of the second thermoplastic portion is greater than or equal to the thickness of the fusible member along the axis.
  • a method for manufacturing a terminal busbar in accordance with another exemplary embodiment includes providing first and second busbar portions and a fusible member.
  • the fusible member is integrally formed with and coupled to the first and second busbar portions.
  • the fusible member has a top surface, a bottom surface, and a first portion with a groove or an aperture disposed therein.
  • the method further includes overmolding a thermoplastic layer on the first portion of the fusible member such that the thermoplastic layer encapsulates the first portion and the groove or the aperture.
  • the thermoplastic layer has a first thermoplastic portion disposed on the top surface of the fusible member, and a second thermoplastic portion disposed on the bottom surface of the fusible member.
  • a thickness of the first thermoplastic portion is greater than or equal to the thickness of the fusible member along an axis.
  • the axis extends through the thermoplastic layer and the fusible member and is perpendicular to the top and bottom surfaces of the fusible member.
  • a thickness of the second thermoplastic portion is greater than or equal to the thickness of the fusible member along the axis.
  • FIG. 1 is a schematic of a battery module
  • FIG. 2 is a cross-sectional schematic of the battery module of FIG. 1 ;
  • FIG. 3 is an enlarged schematic of a portion of the battery module of FIG. 2 ;
  • FIG. 4 is a schematic of a battery cell interconnect assembly utilized in the battery module of FIG. 1 ;
  • FIG. 5 is an enlarged schematic of a portion of the battery module of FIG. 1 ;
  • FIG. 6 is a schematic of a terminal busbar utilized in the battery cell interconnect assembly of FIG. 4 in accordance with an exemplary embodiment
  • FIG. 7 is a top view of the terminal busbar of FIG. 6 ;
  • FIG. 8 is a side view of the terminal busbar of FIG. 6 ;
  • FIG. 9 is a bottom view of the terminal busbar of FIG. 6 ;
  • FIG. 10 is an enlarged view of a portion of the terminal busbar of FIG. 6 before an overmolded thermoplastic layer is disposed thereon;
  • FIG. 11 is another enlarged view of the portion of the terminal busbar of FIG. 6 after the overmolded thermoplastic layer is disposed thereon;
  • FIG. 12 is a cross-sectional schematic of a portion of the terminal busbar of FIG. 11 taken along lines 12 - 12 , that illustrates a groove therein;
  • FIG. 13 is a cross-sectional schematic of a portion of the terminal busbar of FIG. 11 taken along lines 13 - 13 , that illustrates a fusible portion of a fusible member;
  • FIG. 14 is a flowchart of a method for manufacturing the terminal busbar of FIG. 1 in accordance with another exemplary embodiment
  • FIG. 15 is a block diagram of an overmolding device utilized to apply the overmolded thermoplastic layer to a terminal busbar;
  • FIG. 16 is a schematic of an alternative embodiment of a terminal busbar having a fusible member with an aperture extending therethrough, before the overmolded thermoplastic layer is disposed thereon;
  • FIG. 17 is a schematic of the terminal busbar of FIG. 16 after the overmolded thermoplastic layer is disposed thereon;
  • FIG. 18 is a cross-sectional schematic of the terminal busbar of FIG. 17 taken along lines 18 - 18 ;
  • FIG. 19 is a flowchart of a method for manufacturing the terminal busbar of FIG. 17 in accordance with another exemplary embodiment.
  • the battery module 20 includes battery cells 30 , 32 , 34 , 36 , 38 , 40 , 42 , 44 , 46 , 48 , 50 , 52 , 54 , 56 , 58 , 60 , 62 , 64 , 66 , 68 , 70 , 72 , 74 , 76 and a battery cell interconnect assembly 100 .
  • an advantage of the battery module 20 is that the battery module 20 utilizes a terminal busbar 330 having a fusible member 504 and an overmolded thermoplastic layer 506 .
  • a portion of the fusible member 504 melts to form an open electrical state within the terminal busbar 330 to prevent further excessive current flow which may damage the battery module 20 .
  • the overmolded thermoplastic layer 506 prevents melted portions of the fusible member 504 from being dislodged from the overmolded thermoplastic layer 506 . Further, the overmolded thermoplastic layer 506 prevents secondary arcing between a melted portion of the fusible member 504 and a remaining portion of the fusible member 504 .
  • a “fusible member” of a terminal busbar is an integrally formed portion of the terminal busbar that has a reduced cross-sectional area utilizing either a groove or an aperture therein to transition from a closed electrical state to an open electrical state when an excessive current level is flowing through the fusible member for a predetermined amount of time.
  • each of the battery cells 30 - 76 have an identical structure, so only the structure the battery cell 30 will be discussed in greater detail herein for purposes of simplicity.
  • the battery cell 30 includes terminals 101 , 102 disposed at opposite ends of a pouch body 103 .
  • the battery cell 30 is a lithium-ion pouch battery cell.
  • the battery cell 30 could comprise other types of battery cells known to those skilled in the art.
  • the battery cells 30 - 76 are stacked against one another and are electrically coupled in series to one another.
  • the end battery cells 30 and 76 are electrically coupled to the terminal busbars 330 , 360 respectively.
  • the battery cell interconnect assembly 100 is physically and electrically coupled to terminals of the battery cells 30 - 76 at a first end of the battery cells 30 - 76 .
  • the battery cell interconnect assembly 100 includes a rectangular plastic body 320 , a terminal busbar 330 , interconnect members 332 , 334 , 336 , 338 , 340 , 342 , 344 , 346 , 348 , 350 , 352 , and a terminal busbar 360 . It should be understood that another battery cell interconnect assembly (not shown) could be coupled to terminals of the battery cells 30 - 76 at a second end of the battery cells 30 - 76 .
  • the rectangular plastic body 320 is provided to hold the remaining components of the battery cell interconnect assembly 100 thereon.
  • the rectangular plastic body 320 includes a top surface 380 and a bottom surface 382 (shown in FIG. 3 ). Further, the rectangular plastic body 320 includes apertures 400 , 402 , 404 , 406 , 408 , 410 , 412 , 414 , 416 , 418 , 420 , 422 extending therethrough for receiving associated terminals of the battery cells 30 - 76 therethrough.
  • the interconnect members 332 - 352 are coupled to the rectangular plastic body 320 and are used to connect associated terminals of the battery cells 30 - 64 to one another.
  • the interconnect members 332 - 352 are constructed of either copper or aluminum.
  • the interconnect member 332 is disposed adjacent to the apertures 400 , 402 and receives terminals from a first end of the battery cells 32 , 34 thereon, and the interconnect member 334 is disposed adjacent to the apertures 402 , 404 and receives terminals from a first end of the battery cells 36 , 38 thereon. Further, the interconnect member 336 is disposed adjacent to apertures 404 , 406 and receives terminals from a first end of the battery cells 40 , 42 thereon, and the interconnect member 338 is disposed adjacent to apertures 406 , 408 and receives terminals from a first end of the battery cells 44 , 46 thereon.
  • the interconnect member 340 is disposed adjacent to apertures 408 , 410 and receives terminals from a first end of the battery cells 48 , 50 thereon, and the interconnect member 342 is disposed adjacent to apertures 410 , 412 and receives terminals from a first end of the battery cells 52 , 54 thereon. Further, the interconnect member 344 is disposed adjacent to apertures 412 , 414 and receives terminals from a first end of the battery cells 56 , 58 thereon, and the interconnect member 346 is disposed adjacent to apertures 414 , 416 and receives terminals from a first end of the battery cells 60 , 62 thereon.
  • the interconnect member 348 is disposed adjacent to apertures 416 , 418 and receives terminals from a first end of the battery cells 64 , 66 thereon
  • the interconnect member 350 is disposed adjacent to apertures 418 , 420 and receives terminals from a first end of the battery cells 68 , 70 thereon
  • the interconnect member 352 is disposed adjacent to apertures 420 , 422 and receives terminals from a first end of the battery cells 72 , 74 thereon.
  • the terminal busbars 330 , 360 are disposed on opposite ends of the series stack of the battery cells 30 - 76 and a voltage between the terminal busbars 330 , 360 is equal to the sum of the voltages output by the battery cells 30 - 76 .
  • the terminal busbar 330 is coupled to the rectangular plastic body 320 .
  • the terminal busbar 330 includes a first busbar portion 500 , a second busbar portion 502 , a fusible member 504 , an overmolded thermoplastic layer 506 , and a post 508 (shown in FIG. 4 ), and an axis 510 (shown in FIG. 12 ).
  • the first busbar portion 500 , the second busbar portion 502 , and the fusible member 504 are integrally formed with one another from a single sheet of metal such as copper or aluminum for example, and are electrically conductive.
  • the terminal busbar 330 utilizes the fusible member 504 and the overmolded thermoplastic layer 506 .
  • a portion of the fusible member 504 melts to form an open electrical state within the terminal busbar 330 to prevent further excessive current flow which may damage the battery module 20 .
  • the overmolded thermoplastic layer 506 prevents melted portions of the fusible member 504 from being dislodged from the overmolded thermoplastic layer 506 .
  • the overmolded thermoplastic layer 506 prevents secondary arcing between a melted portion of the fusible member 504 and a remaining portion of the fusible member 504 .
  • the first busbar portion 500 has a coupling plate 520 , first and second tab portions 522 , 524 , and a hole 526 .
  • the first and second tab portions 522 , 524 are disposed on opposite ends of the coupling plate 520 and extend substantially perpendicular to the coupling plate 520 .
  • the first and second tab portions 522 , 524 are utilized to couple the terminal busbar 330 to the rectangular plastic body 320 .
  • the hole 526 is sized and shaped to receive the post 508 (shown in FIG. 4 ) therethrough.
  • the post 508 is physically and electrically coupled to the coupling plate 520 and extends substantially perpendicular to the coupling plate 520 .
  • the second busbar portion 502 has a top plate portion 540 and first and second side plate portions 542 , 544 .
  • the first and second side plate portions 542 , 544 are coupled to opposite sides of the top plate portion 540 and extend downwardly and substantially perpendicular to the top plate portion 540 .
  • the U-shaped configuration of the second busbar portion 502 that includes the top plate portion 540 and the first and second side plate portions 542 , 544 allows for an increased surface area for welding the terminals of associated battery cells thereon.
  • the fusible member 504 is coupled to and between the coupling plate 520 of the first busbar portion 500 and the top plate portion 540 of the second busbar portion 502 .
  • the fusible member 504 has a top surface 570 , a bottom surface 572 , and a portion 562 with a groove 560 disposed therein having a decreased cross-sectional area.
  • the portion 561 melts when an excessive current (e.g., current flow during a short-circuit condition of the battery module 20 ) is flowing through the terminal busbar 330 for a time interval such that portion 562 transitions to an open electrical state (e.g., acts like an electrical fuse) to prevent further current flow.
  • an excessive current e.g., current flow during a short-circuit condition of the battery module 20
  • an open electrical state e.g., acts like an electrical fuse
  • the portion 561 has a cross-sectional area that is less than the cross-sectional area of other portions of the fusible member 504 , so that the portion 561 is a first portion of the fusible member 504 to melt when an excessive current is flowing through the fusible member 504 for a time interval.
  • the overmolded thermoplastic layer 506 is provided to prevent a melted portion (e.g., melted portion of portion 561 ) of the fusible member 504 from being dislodged outside of the overmolded thermoplastic layer 506 and to prevent secondary arcing between the melted portion and a remaining portion of the fusible member 504 .
  • the overmolded thermoplastic layer 506 encapsulates and covers the portion 561 of the fusible member 504 and the groove 560 therein.
  • the overmolded thermoplastic layer 506 includes first, second, and third thermoplastic portions 591 , 592 , 593 .
  • the first thermoplastic portion 591 is disposed on the top surface 570 of the fusible member 504 and extends outwardly therefrom.
  • the second thermoplastic portion 592 is disposed on the bottom surface 572 of the fusible member 504 and extends outwardly therefrom.
  • the third thermoplastic portion 593 fills the groove 560 .
  • An axis 510 extends through the overmolded thermoplastic layer 506 and the fusible member 504 that is perpendicular to the top surface 570 and the bottom surface 572 of the fusible member 504 .
  • the overmolded thermoplastic layer 506 has a thickness along the axis 510 that is greater than a thickness of the fusible member 504 along the axis 510 .
  • a thickness of the first thermoplastic portion 591 is greater than or equal to the thickness of the fusible member 504 along the axis 510 .
  • a thickness of the second thermoplastic portion 592 is greater than or equal to the thickness of the fusible member 504 along the axis 510 . It is important that the thicknesses of each of the first and second thermoplastic portions 591 , 592 are greater than or equal to a thickness of the fusible member 504 along the axis 510 so that the thermoplastic portions 591 , 592 have a sufficient volume to flow into a region previously occupied by a melted portion of the fusible member 504 to prevent secondary arcing between the melted portion and a remaining portion of the fusible member 504 , and to completely encapsulate the melted portion such that the melted portion is contained within the overmolded thermoplastic layer 506 .
  • the overmolded thermoplastic layer 506 is an overmolded thermoset plastic layer that has a softening temperature which is less than a melting temperature of the fusible member 504 .
  • An advantage of using an overmolded thermoset plastic layer is that a difference between a softening temperature and a higher melting temperature thereof is relatively large which allows the thermoset plastic material layer to soften at the softening temperature and to flow into a region previously occupied by a melted portion of the fusible member 504 to prevent secondary arcing between the melted portion and a remaining portion of the fusible member 504 without dripping off of the fusible member 504 .
  • the fusible member 330 melts to form an open electrical state between the first and second busbar portions 500 , 502 , and the overmolded thermoplastic layer 506 prevents a melted portion of the fusible member 504 from being dislodged from the overmolded thermoplastic layer 506 .
  • the layer 506 when the overmolded thermoset plastic layer 506 reaches a softening temperature, the layer 506 has a softened state, and when the melted portion of the fusible member 504 is formed at a higher melting temperature, the layer 506 flows into a region previously occupied by a melted portion of the fusible member 504 to prevent secondary arcing between the melted portion and a remaining portion of the fusible member 504 , and to completely encapsulate the melted portion to prevent the melted portion from being dislodged from the overmolded thermoplastic layer 506 .
  • the terminal busbar 360 is coupled to the rectangular plastic body 320 .
  • the terminal busbar 360 is electrically coupled to the battery cell 76 .
  • a user provides the first and second busbar portions 500 , 502 and the fusible member 504 .
  • the fusible member 504 is integrally formed with and coupled to the first and second busbar portions 500 , 502 .
  • the fusible member 504 has a top surface 570 , a bottom surface 272 , and a first portion 561 with a groove 560 (shown in FIG. 10 ) disposed therein.
  • an overmolding device 604 overmolds a thermoplastic layer 506 on the first portion 561 of the fusible member 504 such that the thermoplastic layer 506 encapsulates the first portion 561 and the groove 560 .
  • the thermoplastic layer 506 having a first thermoplastic portion 591 disposed on the top surface 570 of the fusible member 504 , and a second thermoplastic portion 592 disposed on the bottom surface 572 of the fusible member 504 .
  • a thickness of the first thermoplastic portion 591 is greater than or equal to the thickness of the fusible member 504 along an axis 510 .
  • the axis 510 extends through the thermoplastic layer 506 and the fusible member 504 and is perpendicular to the top and bottom surfaces 570 , 572 of the fusible member 504 .
  • a thickness of the second thermoplastic portion 592 is greater than or equal to the thickness of the fusible member 504 along the axis 510 .
  • the terminal busbar 630 includes a first busbar portion 700 , a second busbar portion 702 , a fusible member 704 , an overmolded thermoplastic layer 706 , and a post 708 (shown in FIG. 4 ).
  • the first busbar portion 700 and the second busbar portion 70 are identical in structure to the first busbar portion 500 and the second busbar portion 502 .
  • the thermoplastic layer 706 is substantially identical in structure to the thermoplastic layer 506 except that the thermoplastic layer 705 encapsulates and fills an aperture 750 instead of a groove.
  • the terminal busbar 630 has a first portion 761 with an aperture 750 extending therethrough instead of a groove extending therein.
  • the overmolded thermoplastic layer 706 encapsulates and covers the fusible member 704 and the aperture 750 .
  • a user provides the first and second busbar portions 700 , 702 and the fusible member 704 .
  • the fusible member 704 is integrally formed with and coupled to the first and second busbar portions 700 , 702 .
  • the fusible member 704 has a top surface 770 , a bottom surface 772 , and a first portion 761 with an aperture 750 extending therethrough.
  • the overmolding device 604 overmolds a thermoplastic layer 706 on the first portion 749 of the fusible member 704 such that the thermoplastic layer 706 encapsulates the first portion 761 and the aperture 750 .
  • the thermoplastic layer 706 having a first thermoplastic portion 791 disposed on the top surface 770 of the fusible member 704 , and a second thermoplastic portion 792 disposed on the bottom surface 772 of the fusible member 704 .
  • a thickness of the first thermoplastic portion 791 is greater than or equal to the thickness of the fusible member 704 along an axis 710 .
  • the axis 710 extends through the thermoplastic layer 706 and the fusible member 704 and is perpendicular to the top and bottom surfaces 770 , 772 of the fusible member 704 .
  • a thickness of the second thermoplastic portion 792 is greater than or equal to the thickness of the fusible member 704 along the axis 710 .
  • each inventive terminal busbar described herein provides a substantial advantage over other terminal busbars.
  • an advantage of each inventive terminal busbar is that the terminal busbar has a fusible member and an overmolded thermoplastic layer.
  • a portion of the fusible member melts to form an open electrical state within the terminal busbar to prevent further excessive current flow which may damage the battery module.
  • the overmolded thermoplastic layer prevents melted portions of the fusible member from being dislodged from the overmolded thermoplastic layer.
  • the overmolded thermoplastic layer prevents secondary arcing between a melted portion of the fusible member and a remaining portion of the fusible member.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Connection Of Batteries Or Terminals (AREA)
  • Fuses (AREA)
  • Battery Mounting, Suspending (AREA)
US16/242,058 2019-01-08 2019-01-08 Terminal busbar Active 2039-07-13 US11063320B2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US16/242,058 US11063320B2 (en) 2019-01-08 2019-01-08 Terminal busbar
CN202080003233.0A CN112292746B (zh) 2019-01-08 2020-01-03 端子汇流条
EP20737976.9A EP3793032A4 (fr) 2019-01-08 2020-01-03 Barre omnibus à borne
KR1020207035315A KR102757238B1 (ko) 2019-01-08 2020-01-03 터미널 버스 바
PCT/KR2020/000128 WO2020145581A1 (fr) 2019-01-08 2020-01-03 Barre omnibus à borne
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JP2021526306A (ja) 2021-09-30
JP7118499B2 (ja) 2022-08-16
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US20200220143A1 (en) 2020-07-09
WO2020145581A1 (fr) 2020-07-16
KR20210102838A (ko) 2021-08-20
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KR102757238B1 (ko) 2025-01-21
CN112292746A (zh) 2021-01-29

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